RULE 4682 - POLYSTYRENE FOAM, POLYETHYLENE, AND POLYPROPYLENE MANUFACTURING (Adopted May 21, 1992; Amended December 17, 1992; Amended June 16, 1994)

1.0 Purpose

The purpose of this rule is to limit emissions of VOC and trichlorofluoromethane (CFC-11) and dichlorofluoromethane (CFC-12) from manufacturing and processing of polystyrene foam, polyethylene, and polypropylene and from the storage of VOC blowing agents.

2.0 Applicability

The provisions of this rule shall apply to any polystyrene foam, polyethylene, and polypropylene manufacturing and processing operations.

3.0 Definitions

For the purpose of this rule, the following definitions shall apply:

3.1 Blowing Agent: any liquid, or gaseous material, including VOCs, that facilitates the formation of a cellular product from raw polymeric material.



3.2 Controllable VOC Emission Sources: fluff silos or bins, reclaim extruders, condenser devolatizer vents, styrene recovery unit vents, and reclaim die hood exhausts in which materials manufactured with a VOC blowing agent are processed, or are stored, and from which emissions are vented to the atmosphere.

3.3 Chlorofluorocarbon (CFC): any chlorinated fluorinated compound of carbon, excluding chlorodifluoromethane (HCFC-22), dichlorotrifluoromethane (HCFC-123), tetrafluoroethane (HFC-134a), dichlorofluoroethane (HCFC-141b), and chlorodifluoroethane (HCFC-142b).

3.4 Fluff Silo or Bin: a container utilized for the storage of ground polystyrene foam for recycling.

3.5 Polyethylene (High and Low Density): linear thermoplastic polymers of ethylene with densities from 0.94 gram per cubic centimeter or higher.



3.6 Polymeric Material: a multi-molecular compound or mixture of compounds formed by polymerization and consisting essentially of repeating structural units.



3.7 Polypropylene: a high molecular weight thermoplastic crystalline polymer of propylene.



3.8 Polystyrene: a thermoplastic material which is a polymer of styrene.



3.9 Reclaim Die Hood Exhaust: an exhaust hood above reclaim extruder die intended to remove VOCs which escape from the extruder die.



3.10 Reclaim Extruder: equipment used to reprocess ground polystyrene foam into polystyrene pellets.



3.11 Reclaim Extruder Vent: the vent or opening through which emissions are expelled from the reclaim extruder.



3.12 Volatile Organic Compound (VOC): defined in Rule 1020 (Definitions).

4.0 Exemptions

The provisions of Sections 5.1 and 5.2 shall not apply to manufacturing and processing operations using polymeric materials containing less than 1 percent volatile organic compounds by weight, and not using a blowing agent in their process.

5.0 Requirements

5.1 No person shall operate controllable VOC emission sources at a polystyrene foam, polyethylene, or polypropylene manufacturing or processing operation unless one of the following VOC emission reduction methods is provided:



5.1.1 A blowing agent other than a VOC or trichlorofluoromethane (CFC-11) or dichlorodifluoromethane (CFC-12) is exclusively used; or



5.1.2 A collection system designed to achieve at least 90 percent VOC capture efficiency, and a thermal oxidizer which abates captured VOC emissions by at least 95 percent by weight; or



5.1.3 VOC emissions are controlled by a method which achieves an emission reduction equivalent to Section 5.1.2 and which does not include the use of trichlorofluoromethane (CFC-11) or dichlorodifluoromethane (CFC-12), and is approved by the APCO.



5.2 No person shall place, hold or store any VOC blowing agent in any stationary tank, reservoir or container having a capacity greater than 200 gallons unless one (1) of the following emission control systems is provided:



5.2.1 The container is a pressure vessel maintaining a working pressure at all times sufficient to prevent release of VOC emissions to the atmosphere under normal operating conditions; or



5.2.2 The container is equipped with an emission control device or system which collects and disposes of VOC emissions, and which achieves and maintains a vapor recovery/control efficiency of at least 95 percent by weight.

6.0 Administrative Requirements

6.1 Recordkeeping



6.1.1 Any person subject to the provisions of this rule, including exempt facilities, shall maintain records of operation, including but not limited to the amount of material processed, the equipment used, and the type of the blowing agent used. Records shall be maintained with a minimum monthly totals with the ability to calculate daily averages in any given month. Such records shall be retained for two years, and be made available upon request.



6.1.1 Any person using an emissions control system as a means of complying with this rule, shall maintain daily records of key system operating and maintenance procedures which will demonstrate continuous operation and compliance of the emission control device. Key system operating parameters are those necessary to ensure compliance with VOC emission requirements such as temperature, pressures, and flowrates. Such records shall be retained for two years, and be made available upon request.



6.2 Test Methods



6.2.1 The control efficiency of any air pollution control equipment shall be determined using EPA Methods 25 and 25A for measuring total gaseous organic concentrations at the inlet and outlet of the control device.



6.2.2 EPA Method 18 or ARB Test Method 422 for determination of exempt compounds and halogenated blowing agents.

7.0 Compliance Schedule

Any person who becomes subject to the requirements of this rule shall comply with the following increments of progress:

7.1 By December 16, 1994, submit to the APCO a complete application for Authority to Construct including a control plan which includes all steps and construction schedules to be taken to achieve compliance with this rule



7.2 By June 16, 1996, demonstrate full compliance with the provisions of this rule.